Driver’s Handbook
Mack EPA2010 Emissions Operator’s Manual
Foreword
This manual contains information concerning the operation and function
of the Mack Engines. Please keep this manual in the vehicle at all times.
Note: Illustrations in this manual are used for reference only and may
differ slightly from the actual vehicle. However, key components
addressed in this document are represented as accurately as possible.
The National Highway Traffic Safety Administration (NHTSA) and
Mack Trucks, Inc. should be informed immediately if you believe that
the vehicle has a defect that could cause a crash, injury or death.
Contact NHTSA by calling the Auto Safety Hotline at 1 (888) 327-4236,
by writing to NHTSA, U.S. Department of Transportation, Washington,
DC 20590, by TTY at 1 (800) 424-9153, or visit their website at
www.nhtsa.dot.gov.
Mack Trucks, Inc.
Greensboro, NC USA
Order number: PV776-21414253
© 2009 Mack Trucks, Inc., Greensboro, NC USA
All rights reserved. No part of this publication may be reproduced,
stored in retrieval system, or transmitted in any forms by any means,
electronic, mechanical, photocopying, recording or otherwise, without
the prior written permission of Mack Trucks, Inc.
Contents
Overview of the Mack Engines ........................................................
Introduction ......................................................................................
Fuel ...................................................................................................
Bio Diesel .........................................................................................
Engine Oil .........................................................................................
Engine Operation ..............................................................................
Engine Overview, MP7 and MP8 Left Side View ............................
Engine Overview, MP7 and MP8 Right Side View ..........................
Engine Overview, MP10 Left Side View .........................................
Engine Overview,MP10 Right Side View ........................................
1
1
2
2
2
3
5
6
7
8
Mack, EPA2010 Emissions Solution ................................................ 9
Exhaust Aftertreatment System ........................................................ 9
Safety Information ......................................................................... 11
Exhaust Aftertreatment System Components and Operation ........ 12
Selective Catalytic Reduction (SCR) .......................................... 12
Diesel Exhaust Fluid (DEF) ........................................................ 14
Aftertreatment Control Module (ACM) ...................................... 15
Aftertreatment Diesel Particulate Filter (DPF) ............................ 16
Exhaust Aftertreatment System Operation .................................. 17
Driver Warnings and On Board Diagnostics (OBD) ...................... 25
On Board Diagnostics (OBD) ...................................................... 25
Instrument Cluster ....................................................................... 25
Malfunction Indicator Lamp (MIL) ............................................. 27
Aftertreatment DEF Tank Level - Driver Warning &
Inducement .................................................................................. 28
Aftertreatment DEF Quality - Driver Warning & Inducement .... 29
Misfilling Diesel or Aftertreatment DEF Tanks .......................... 30
SCR Tampering - Driver Warning & Inducement ....................... 31
Ambient Air Temperature (AAT) ................................................ 32
Warranty and Maintenance ............................................................ 33
Exhaust Aftertreatment System Maintenance ............................. 33
Emissions Maintenance ............................................................... 33
Engine Maintenance Intervals ..................................................... 33
Oil Change Intervals .................................................................... 35
Emissions Control System Warranty ........................................... 36
Safety Information
IMPORTANT: Before driving this vehicle, be certain that you have read and that you
fully understand each and every step of the driving and handling information in this
manual. Be certain that you fully understand and follow all safety warnings.
IT IS IMPORTANT THAT THE FOLLOWING INFORMATION BE READ,
UNDERSTOOD AND ALWAYS FOLLOWED.
The following types of advisories are used throughout this manual:
DANGER
Danger indicates an unsafe practice that could result in serious personal injury or death.
A danger advisory banner is in white type on a black background with a black border.
WARNING
Warning indicates an unsafe practice that could result in personal injury. A warning
advisory banner is in black type on a gray background with a black border.
CAUTION
Caution indicates an unsafe practice that could result in damage to the product. A caution
advisory is in black type on a white background with a black border.
Note: Note indicates a procedure, practice, or condition that must be followed in order for
the vehicle or component to function in the manner intended.
CALIFORNIA PROPOSITION 65 WARNING
Diesel engine exhaust and some of its constituents are known to the State of California to
cause cancer, birth defects and other reproductive harm.
CALIFORNIA PROPOSITION 65 WARNING
Battery posts, terminals and other related accessories contain lead and lead compounds,
chemical known to the State of California to cause cancer and other reproductive harm.
Batteries also contain other chemicals known to the State of California to cause cancer.
Wash hands after handling.
Important
Your new Mack truck contains many new technological advancements that may require new
servicing techniques and methods. An authorized Mack truck dealer is in the best position
to provide technicians who have the necessary training, experience and tools to properly
service your truck.
Overview of the Mack Engines
1
Introduction
In 2010, the Mack engine family will consist
of three engines: MP7, MP8 and MP10.
The Mack engines meet the very stringent
new emissions standards which apply to
all heavy-duty diesel engines built after
January 1, 2010 for on-highway trucks. The
new standards for EPA2010 requires 83%
reduction in nitrogen oxide (NOx) and 0%
reduction in Particles (Pt) relative to US07.
Key Features of the Mack Engines:
•
•
•
•
•
•
Improved Fuel Economy
Extended Oil Drain Intervals
Improved Cooling Capacity
Low Maintenance Catalyzed
Aftertreatment Diesel Particulate Filter
(DPF)
Enhanced Engine Brake Performance
Selective Catalytic Reduction (SCR)
2
Overview of the Mack Engines
Fuel
CAUTION
Diesel engines for 2010 and later model
year vehicles are designed to operate only
with Ultra Low Sulfur Diesel (ULSD)
fuel. Use of fuel other than ULSD will
reduce the efficiency and durability of the
engine, permanently damage the advanced
emission control systems, reduce fuel
economy and possibly prevent the engine
from running at all. Manufacturer’s
warranties are likely to be rendered void
by usage of improper or incorrect fuel,
and usage of fuels other than ULSD fuel
in diesel-powered vehicles is illegal and
punishable with civil penalties. Use of
fuel additives to compensate for the lower
sulfur content is NOT recommended by
Mack Trucks, Inc..
Fuel sold for use in diesel-powered engines
for 2010 and later model year vehicles may
only contain a maximum sulfur content of
0.0015% by weight. This was done to reduce
particle emissions in the exhaust.
Bio Diesel
The only BioDiesel Fuel approved by Mack
Trucks, Inc. for use in Mack Engines is Soy
Methyl Ester (SME or SOME) in blends up
to B5 Concentration (5% blend).
Note: Although higher concentrations are
available, concentration up to B5 (maximum)
are the only blends currently approved by
Mack Trucks, Inc.
Engine Oil
EO-O Premium Plus (or VDS-4) diesel
engine oil is mandatory for use in all 2010
emission compliant Mack engines. Chassis
equipped with a 2010 emission compliant
engine, which can be identified by the
presence of an Aftertreatment Selective
Catalytic Reduction (SCR) system, also
require the use of Ultra Low Sulfur Diesel
(ULSD) fuel. EO-O Premium Plus oils
exceed the new API service category CJ-4.
Overview of the Mack Engines
3
Engine Operation
DANGER
Do not use ether or other combustible
starting aids in any Mack engine.
Introduction of ether or similar starting
aids could cause a fire or explosion
resulting in severe property damage,
serious personal injury or death.
CAUTION
DO NOT crank the engine for more than
30 seconds at a time; wait 15 minutes
after each try to allow the starter to cool.
Failure to follow these instructions could
cause starter damage.
Note: Some starters are equipped with
starter protection. If the engine is running,
the starter temperature is too high, the
transmission is not in neutral or the clutch
pedal is not depressed, starter engagement
is inhibited.
Allow the engine to slow down and idle for
3 to 5 minutes before shutting it off. This
allows the turbocharger to cool down and the
cooling system to dissipate the engine heat.
Switch the engine off by turning the ignition
key to the OFF position.
CAUTION
Shutting off an engine immediately after
high speed or full load operation can
damage the turbocharger and cause heat
stress in the engine. Always let the engine
idle for 3 to 5 minutes before shutting it
off.
Mack Trucks, Inc. does not recommend
the use of winterfronts, shutters or any
other shield in front of the grille or radiator
package under normal circumstances.
Today’s electronically controlled engines
are designed to operate in cold temperatures
without a winterfront. These devices, if
not used properly, can cause higher exhaust
gas temperatures, power loss, excessive fan
usage, failure of the charge-air-cooler and
a reduction in fuel economy. Winterfronts
can be used in the wintertime during very
cold weather if used properly. In these cases,
engine coolant and intake air temperatures
must also be carefully monitored and
controlled. Please see your authorized
Mack Truck dealer for Mack recommended
winterfronts.
CAUTION
Mack is now using the ambient air
temperature (AAT) sensor for OBD
monitoring. If a customer installs a
winterfront or blocks the radiator opening
and blocks airflow to the sensor, they will
likely set an OBD diagnostic trouble code
(DTC) for inaccurate sensor data due to
restricted airflow across the sensor.
4
Overview of the Mack Engines
Engine Shutdown System
DANGER
Failure to take the necessary precautions
when the STOP telltale is on can result in
automatic engine shutdown and the loss of
power steering. Vehicle crash can occur.
The engine shutdown system will
automatically derate or stop the engine when
one or more of the conditions listed below
reaches a critical stage:
•
•
•
•
High Engine Coolant Temperature
(ECT)
Low Engine Oil Pressure (EOP)
Low Engine Coolant Level (ECL)
High Crankcase Pressure (CCP)
When the shutdown is activated, the telltales
come on along with display symbols and the
buzzer is also activated. After a brief time,
the engine shuts down. Find a safe place to
pull off the road as soon as possible.
After the engine has been shut down by
the system, turn the ignition key to the off
position. If necessary, the engine can be
restarted for a brief time so that the vehicle
may be pulled off the road.
The alarm will remain activated until repairs
have been made to correct the problem that
caused the shutdown.
CAUTION
Continuously restarting the engine once
the shutdown system is active may result
in severe engine damage.
Refer to the Driver Information Display
manual for information about the display
symbols.
W3031624
Overview of the Mack Engines
Engine Overview, MP7 and MP8 Left Side View
W2006034
MP8 Engine Shown, MP7 Engine Similar
1. Breather Tube
9. Fuel Filter
2. Intake Manifold
10. Hand-Priming Pump
3. Air Compressor
11. Crankcase Ventilator
4. Power Steering Pump
12. Alternator
5. Fuel Pump
13. AC Compressor
6. Engine Control Module (ECM)
14. Alternator/AC Compressor Belt
7. Fuel Filter
15. Fan/Coolant Pump Belt
8. Fuel/Water Separator
16. EGR Mixing Chamber
5
6
Overview of the Mack Engines
Engine Overview, MP7 and MP8 Right Side View
W2006035
MP8 Engine Shown, MP7 Engine Similar
17. Exhaust Manifold
24. Venturi Pipe
18. Valve Cover
25. Oil Filters
19. Intake Air Heater (IAH) optional
26. Oil Pan
20. Thermostat
27. EGR Cooler
21. Belt Tensioner
28. Turbocharger
22. Coolant Pump
29. Starter Motor
23. Coolant Filter
30. EGR Valve
Overview of the Mack Engines
Engine Overview, MP10 Left Side View
W2006037
1. Breather Tube
9. Fuel/Water Separator
2. Intake Manifold
10. Fuel Filter
3. Air Compressor
11. Hand-Priming Pump
4. Power Steering Pump
12. Alternator
5. Fuel Pump
13. AC Compressor
6. Crankcase Ventilator
14. Alternator/AC Compressor Belt
7. Engine Control Module (ECM)
15. Fan/Coolant Pump Belt
8. Fuel Filter
16. Venturi Pipe
17. EGR Mixing Chamber
7
8
Overview of the Mack Engines
Engine Overview,MP10 Right Side View
W2006036
18. Exhaust Manifold
24. Coolant Filter
19. Valve Cover
25. Oil Filters
20. Intake Air Heater (IAH)
26. EGR Cooler
21. Thermostat
27. Oil Pan
22. Belt Tensioner
28. Starter Motor
23. Coolant Pump
29. Turbocharger
30. EGR Valve
Mack, EPA2010 Emissions Solution
9
Exhaust Aftertreatment System
CHU, CXU, GU and TD Standard System View
W2029933
1. Selective Catalytic Reduction (SCR)
Catalyst
3. Aftertreatment Diesel Particulate Filter
(DPF)
2. Aftertreatment DEF Dosing Unit
4.Aftertreatment DEF Tank
10
Mack, EPA2010 Emissions Solution
LEU and MRU Standard System View
W2031562
1. Selective Catalytic Reduction (SCR)
Catalyst
3. Aftertreatment Diesel Particulate Filter
(DPF)
2. Aftertreatment DEF Dosing Unit
4.Aftertreatment DEF Tank
Mack, EPA2010 Emissions Solution
Safety Information
The exhaust aftertreatment system utilizes
technology that oxidizes trapped particles
and unburned hydrocarbons thereby
reducing emissions. This oxidation occurs
during the regeneration process. While
regeneration is occurring, very high exhaust
gas temperatures will occur. In some
vehicles, regeneration can occur when the
vehicle is stationary.
DANGER
Exhaust gases and components can be
at extremely high temperatures during
regeneration. When parking the vehicle,
keep away from any flammable materials,
vapors, or structures.
DANGER
The temperature of the exhaust system
components during the regeneration
process can exceed 350 degrees C (660
F). The exhaust gas leaving the system
can reach 505 degrees C (930 F). Various
factors (including ambient temperature
and duration of the regeneration process)
determine when these components will
return to normal operating temperature
after regeneration has completed.
Be extremely careful around these
hot components. Contact with these
components can result in serious personal
injury.
11
12
Mack, EPA2010 Emissions Solution
Exhaust Aftertreatment System Components and
Operation
Selective Catalytic Reduction (SCR)
Selective Catalytic Reduction (SCR)
is an emissions-reduction technology
with the ability to deliver near-zero
emissions of nitrogen oxides (NOx), a
smog-causing pollutant and greenhouse
gas. SCR’s performance has been proved
in millions of miles of real-world truck
operations in other countries, as well as in
long-term field tests in the U.S.
SCR reduces NOx emissions to
very low levels, while at the same time
delivering excellent fuel economy and
reliability. The system doesn’t change the
design or operation of the basic engine.
Rather, SCR is an aftertreatment system
which converts NOx in the exhaust stream
into harmless gases. Modern diesels already
use exhaust aftertreatment systems, called
diesel particulate filters, to control emissions
of another pollutant, soot (also known
as particulate matter or PM).
SCR works by injecting Diesel
Exhaust Fluid (DEF) into the exhaust. DEF
is a safe, simple solution of water and urea.
DEF works with the heat of the exhaust and
a catalyst to convert NOx into nitrogen and
water vapor - two harmless and natural
components of the air we breathe. The end
result is cleaner air, excellent fuel efficiency
and a reliable emissions control system for
today’s modern diesel engine.
W2031651
1. Diesel Engine
2. Aftertreatment DEF Tank
3. Aftertreatment DEF Pump
4. Aftertreatment DEF Dosing Unit
5. Aftertreatment Diesel Particulate Filter (DPF)
6. Selective Catalytic Reduction (SCR) Catalyst
7. Aftertreatment DEF Tank Gauge
Mack, EPA2010 Emissions Solution
There are 2 different shapes for the SCR
catalysts, they are vertical and horizontal.
The horizontal SCR catalyst comes in 2
different sizes, a full size or a compact. The
vertical SCR catalyst comes in 1 size, with
two different intakes, it will either have a
bottom intake or a side intake.
The Mack SCR system is simple and
effective, with few components. It consists
of a Aftertreatment DEF tank positioned
near the standard diesel tank, plus a
Aftertreatment DEF pump, Aftertreatment
DEF Dosing unit and SCR catalyst. The
advantage of using DEF is that it enables
the engine to use less EGR -- and higher
oxygen levels -- for better combustion,
while meeting the EPA near-zero NOx
emissions requirement of 0.2 g/hp-hr NOx.
By using DEF, we avoid the disadvantages
of increasing EGR to massive levels. This
results in better fuel economy from your
Mack engine.
1
Diesel engine optimized for high
performance, low particle emissions
and low fuel consumption.
2
3
4
5
6
7
13
Aftertreatment DEF tank
The Aftertreatment Control Module
(ACM) continuously monitors and
adjusts the Aftertreatment DEF pump
pressure in response to current engine
load conditions.
DEF is injected into the exhaust gases
in between the Aftertreatment DPF (5)
and the SCR catalyst (6).
Aftertreatment Diesel Particulate Filter
(DPF).
In the SCR catalyst, nitrogen oxides
are transformed into harmless nitrogen
gas and water.
The system notifies the driver when it is
time to refill tank with DEF.
CAUTION
Do not put diesel fuel in the Aftertreatment
DEF tank. Diesel fuel, if sprayed into
the hot exhaust along with the DEF,
could ignite explosively causing a fire
resulting in personal injury or damage to
the exhaust system.
14
Mack, EPA2010 Emissions Solution
Diesel Exhaust Fluid (DEF)
Diesel Exhaust Fluid (DEF) is a reactant
that’s key to the SCR process. It’s a nontoxic,
aqueous solution of 32.5% urea and 67.5%
water. Urea is a compound of nitrogen that
turns to ammonia when heated. It is used
in a variety of industries, perhaps most
commonly as a fertilizer in agriculture. The
fluid is not inflammable, nor is it dangerous
when handled normally. However, it is
highly corrosive to metal, particularly copper
and aluminium. Read the separate section
concerning the handling of DEF solution.
Diesel Exhaust Fluid (DEF) Handling
When handling DEF solution, it is important
that electrical connectors to be connected or
well encapsulated. Otherwise there is a risk
that the DEF will cause oxidation that cannot
be removed. Water or compressed air do not
help, since DEF quickly oxidizes metal. If a
connector comes into contact with the DEF
solution it must be replaced immediately
to prevent the DEF solution from creeping
further into the copper wiring, which takes
place at a speed of about 60 cm (2.4 in) per
hour.
CAUTION
When detaching hoses and components,
do not spill DEF on disconnected
connectors. If DEF is spilled on a
connector, the connector must be replaced
immediately
Things to know about spilled Diesel Exhaust Fluid (DEF)
If urea solution comes into contact with the skin ? rinse with plenty of water and remove
contaminated clothing.
If urea solution comes into contact with the eyes ? rinse for several minutes and call for
medical help if necessary.
If inhaled ? Breathe fresh air and call for medical help if necessary.
Do not allow the DEF solution to come into contact with other chemicals.
The DEF solution is not flammable. If the DEF solution is exposed to high temperatures, it
breaks down into ammonia and carbon dioxide.
The DEF solution is highly corrosive to certain metals, including copper and aluminium.
If the DEF solution is spilled onto the vehicle, wipe off the excess and rinse with water.
Spilled DEF solution can form concentrated white crystals on the vehicle. Rinse off these
crystals with water.
Note: Do not flush DEF spillages into the
normal drain system.
WARNING
DEF spilt onto hot components will
quickly vaporize. Turn your face away!
Mack, EPA2010 Emissions Solution
15
Diesel Exhaust Fluid (DEF) Consumption
DEF consumption is related to fuel
consumption. A highway truck may travel
225-300 miles or more on one gallon of DEF.
If a driver runs out of DEF a gauge much
like a fuel gauge will indicate the level of
DEF in the tank. A DEF low-level warning
will activate when DEF is low. If a driver
runs out of DEF completely, vehicle power
will be reduced to derate mode. When the
DEF tank is refilled, the engine will resume
normal power.
Diesel Exhaust Fluid (DEF) Availability
DEF will be available in 2.5-gallon
containers, 55-gallon drums, 275 gallon
IBC and in bulk storage for fleet locations,
truck stops and dealerships. DEF will
be everywhere drivers are. All major
truck stops, dealers and distributors will
carry DEF. For more information on DEF
and availability please visit the website
www.truckscr.com .
Aftertreatment Control Module (ACM)
The ACM also monitors the following
values in the exhaust aftertreatment
system:
•
Aftertreatment DEF Dosing Absolute
Pressure
•
•
•
Aftertreatment DEF Tank Temperature
•
Aftertreatment DPF Differential
Pressure
•
NOX Sensors
W2029917
The ACM controls the following
components in the exhaust aftertreatment
system:
•
•
•
•
•
•
Aftertreatment DEF Dosing Unit
Aftertreatment DEF Tank Heater Valve
Aftertreatment DEF Line Heaters
Aftertreatment DEF Pump
Aftertreatment DEF Return Valve
Aftertreatment DEF Tank Level Sensor
Aftertreatment DEF Tank Level
Aftertreatment DPF Inlet/Outlet
Temperature
The ACM is a stand alone module.
Depending on your configuration it may be
mounted as part of the DEF tank (as shown
above) or on a bracket near the DEF tank.
16
Mack, EPA2010 Emissions Solution
Aftertreatment Diesel Particulate Filter (DPF)
with the exhaust aftertreatment system. Take
the vehicle to an authorized Mack Truck
dealer immediately.
CAUTION
Use of diesel fuel other than ULSD and
engine oils other than EO-O Premium
Plus (or VDS-4), will adversely affect
performance, efficiency and durability of
the Aftertreatment DPF system and the
engine, to the point where the engine may
not run at all. Manufacturer’s warranties
can also be rendered void due to usage of
improper fuel. Unapproved fuel additives
(including engine oil) are NOT permitted.
Blends of No. 1D and No. 2D grades of
ULSD are recommended and allowable
for cold weather operations.
The exhaust aftertreatment system virtually
eliminates exhaust smoke. Exhaust vapor
(water condensation) may be visible during a
cold start. If exhaust smoke is visible during
engine operation, this indicates a problem
W2030326
Vehicles equipped with a 2010 emission
compliant engine have an exhaust
aftertreatment system which includes a
Selective Catalytic Reduction (SCR) system
and a Catalyzed Aftertreatment Diesel
Particulate Filter (DPF). The Aftertreatment
DPF takes the place of the standard muffler,
and it reduces soot and particulate emissions
into the atmosphere. Soot and other
particulate matter are collected by a filter
where it is eventually oxidized using a
regeneration process. Vehicles equipped
with a Aftertreatment DPF require the
use of EO-O Premium Plus (or VDS-4)
specification high performance diesel engine
oil and Ultra Low Sulfur Diesel (ULSD) fuel.
Mack, EPA2010 Emissions Solution
Exhaust Aftertreatment System Operation
Aftertreatment DPF Regeneration
DPF Smart Switch– This is a three-position switch where the middle position is
neutral.
C0029148
DPF Smart Switch
1. Upper Position – Regeneration
Position
2. Middle Position – Neutral Position
3. Down Position – Inhibit Position (if
equipped)
17
18
Mack, EPA2010 Emissions Solution
CAUTION
During the Aftertreatment DPF Regeneration Required , the exhaust gas temperature will
be elevated. DO NOT park the vehicle with the exhaust outlet near flammable objects
such as trees, awnings, etc. that could be damaged by elevated exhaust gas temperatures.
CAUTION
If the vehicle is in a location that may be hazardous when Aftertreatment DPF
Regeneration Required begins (i.e., in close proximity to flammable materials or
gases, inside tunnels, parked under flammable objects, etc.), the Aftertreatment DPF
Regeneration Required should be stopped (if equipped). If Aftertreatment DPF
Regeneration Required is stopped by the vehicle operator, it must be initiated at a later
time when the vehicle is in a safer location. Aftertreatment DPF Regeneration Required
that are stopped and never restarted at a later time, however, will require that the vehicle
be taken to an authorized Mack Truck dealer to have the Aftertreatment Regeneration
manually started with special service tools.
Note: If Aftertreatment DPF Regeneration Required occurs during vehicle operation,
idle speed may increase when the vehicle is stopped at a traffic light to maintain proper
Aftertreatment DPF Regeneration Required conditions.
There are two types of Aftertreatment DPF
Regeneration Required: Moving and Parked.
Moving Aftertreatment DPF Regeneration
Required only occurs when the vehicle is
moving at uninterrupted highway speed.
Parked Aftertreatment DPF Regeneration
Required is manually initiated when the
vehicle is stationary. This is the standard
configuration. Other configurations are
available.
Mack, EPA2010 Emissions Solution
19
Moving Regeneration
"Moving" regeneration occurs while the vehicle is being driven and can be automatic
(no operator input needed to start regeneration) or manual (operator input needed
to start regeneration). The operator is notified that a regeneration is needed when
the icons on the DPF Smart switch illuminate (refer to Figure listed below).
Note: The vehicle operator should try to maintain vehicle speed during the
regeneration process. If the vehicle must be stopped (at a traffic light for example),
allow the vehicle to idle and do not apply the park brake. Applying the park brake
will disrupt and end a regeneration that started while the vehicle was being driven.
Please refer to the instructions below on how to use the DPF Smart switch during a
regeneration that occurs while the vehicle is being driven.
Moving (Automatic) Regeneration
1
When the icons on the DPF Smart switch light up, maintain vehicle speed if
possible.
2
During regeneration, the icons on the switch will shut off.
3
Regeneration will take between 20 and 30 minutes to complete.
4
To stop regeneration, press the switch down to the inhibit position (if equipped).
When the bottom of the switch is illuminated, regeneration is stopped. The
switch will remain locked in this position and the light will stay illuminated. The
driver has the option of stopping a regeneration if the vehicle is in an area
where elevated exhaust temperatures will pose a hazard (i.e., tunnel, under
trees, in an area where there is flammable material, etc.).
20
Mack, EPA2010 Emissions Solution
Moving (Manual) Regeneration (If Available)
1
When the icons on the DPF Smart switch light up, maintain vehicle speed and
press and hold the top part of the switch momentarily.
2
During regeneration, the icons on the switch will shut off.
3
Regeneration will take between 20 and 30 minutes to complete.
4
To stop regeneration, press the switch down to the inhibit position (if equipped).
When the bottom of the switch is illuminated, regeneration is stopped. The
switch will remain locked in this position and the light will stay illuminated. The
driver has the option of stopping a regeneration if the vehicle is in an area
where elevated exhaust temperatures will pose a hazard (i.e., tunnel, under
trees, in an area where there is flammable material, etc.).
Depending on the vehicle’s set up, it may be possible to perform a parked
regeneration if necessary.
Mack, EPA2010 Emissions Solution
21
Parked Regeneration
Parked regeneration allows the operator to start and/or stop the regeneration
manually when the vehicle is parked and the engine is idling. The operator is
notified that a regeneration is needed when the icons on the DPF Smart switch
illuminate. The operator should perform the regeneration as soon as possible.
Please refer to the instructions below on how to use the DPF Smart switch for
parked regenerations.
1. Move the vehicle to a safe location, apply the park brake and allow the engine to
idle.
WARNING
When a regeneration is in process, the temperature of the exhaust will
be elevated. DO NOT park the vehicle with the exhaust outlet under low
hanging overhead flammable objects such as trees, awnings, etc., that
could be damaged by elevated exhaust temperatures. DO NOT attempt to
regenerate inside a garage or enclosed area if the tail pipe is attached to
an exhaust ventilation system as the hose material may not be rated for
the high temperature.
2. Press and hold the top part of the DPF Smart switch momentarily to initiate
the regeneration.
3. During regeneration, the icons on the switch will shut off. The HEST indicator on
the instrument cluster will light up to notify of high exhaust temperatures.
4. For aftertreatment DPF filter systems which are not Spark Assisted, the engine
speed may ramp as high as 1,100 rpm. For Aftertreatment DPF filter spark assisted
systems, the engine will continue to idle during the regeneration.
5. Regeneration will take between 20 and 30 minutes to complete.
6. After regeneration has completed and the exhaust temperature has returned to
normal, the HEST indicator will shut off.
7. To stop regeneration, press the switch down to the inhibit position (if equipped).
When the bottom of the switch is illuminated, regeneration is stopped. The switch
will remain locked in this position and the light will stay illuminated. The driver has
the option of stopping a regeneration if the vehicle is in an area where elevated
exhaust temperatures will pose a hazard (i.e., tunnel, under trees, in an area where
there is flammable material, etc.).
22
Mack, EPA2010 Emissions Solution
CAUTION
Failure to perform a regeneration in a timely manner after notification may result
in engine derate, a clogged DPF, damage to the DPF and engine shutdown.
DANGER
During the regeneration process (with either system), the temperature of
the exhaust gases will be elevated. DO NOT park or stop for an extended
period under low hanging overhead flammable objects such as trees,
awnings, structures, etc., that could be damaged by elevated exhaust
temperatures. Further, if the vehicle is being operated in an area where
flammable vapors exist, the regeneration process must be interrupted.
Failure to heed these cautions may result in fire or explosion causing
serious personal injury or death.
When regeneration is needed, an icon at the top of the DPF Smart switch will
illuminate to notify the vehicle operator. The DPF Smart switch allows the vehicle
operator to either stop or start regeneration. (Certain conditions must be met,
however, before regeneration can be manually started.)
Note: If the vehicle is in a location that may be hazardous when an active
regeneration begins (i.e., in close proximity to flammable materials or gases),
the regeneration should be stopped by pushing the DPF switch to the "Stop
Regeneration" position.
If an active regeneration is stopped by the vehicle operator, it should be initiated at a
later time when the vehicle is in a safe location. However, if an active regeneration
is stopped too many times, the vehicle must be taken to a MACK service facility.
The service facility will use a service tool to manually initiate the regeneration.
WARNING
The temperature of the exhaust system components during the
regeneration process can exceed 500C (1000F). Various factors (including
ambient temperature and duration of the regeneration process) determine
when these components will return to normal operating temperature
after regeneration has completed. Be extremely careful around these
hot components. Contact with these components can result in serious
personal injury.
Mack, EPA2010 Emissions Solution
23
CAUTION
When the inhibit position is pressed, the switch will remain in a locked position. It
is important, therefore, to immediately set the switch back to the neutral position
when safe to do so. Failure to set the switch back to the neutral position may
result in an engine derate, clogged diesel particulate filter or damage to the filter.
DPF INHIBIT ROAD SPEED LIMITING (RSL)
The DPF Smart Switch can be locked into the DOWN (or Inhibit Regen) position by
the driver (if equipped). If the DPF Smart Switch remains in the locked position, the
following vehicle speed limiting will occur:
1
Vehicle Moving. If vehicle is moving with the DPF Smart Switch in the locked
(DOWN) position, the vehicle speed will decrease down to 16 kph (10 mph)
below the current speed until the driver releases the switch back to the neutral
(MIDDLE) position.
2
Vehicle Stationary and then Moving. If the vehicle is stationary with the DPF
Smart Switch in the locked (DOWN) position and the driver then begins to move
the truck, the vehicle speed will be limited to 16 kph (10 mph) until the driver
releases the switch back to the neutral (MIDDLE) position.
24
Mack, EPA2010 Emissions Solution
Refer to the Exhaust Aftertreatment System
Information sun visor label for additional
Aftertreatment DPF information.
W8029446
Mack, EPA2010 Emissions Solution
25
Driver Warnings and On Board Diagnostics (OBD)
On Board Diagnostics (OBD)
Beginning with your EPA2010 compliant
Vehicle, On Board Diagnostics (OBD)
is introduced. This is very similar
to the On Board Diagnostics (OBD)
system that has been required on
passenger cars for many years.
On Board Diagnostics (OBD)
is a system that monitors the functions of
emissions related components and alert the
vehicle operator to any detected need for an
emission related repair. When the systems
detects a needed repair to an emissions
related component it activates the Malfunction Indicator Lamp (MIL).
The list of emissions related
components can be found in the Warranty
and Maintenance section of this manual
Instrument Cluster
The aftertreatment icons are located in the
instrument cluster per the following images.
CHU, CXU, GU and TD Instrument Cluster
W3031621
1. Malfunction
Indicator Lamp
(MIL)
2. CHECK Lamp
4. High Exhaust
Temperature
(HEST) Lamp
6. Aftertreatment
DEF Tank Gauge
3. Aftertreatment
DEF Low Lamp
26
Mack, EPA2010 Emissions Solution
LEU and MRU Instrument Cluster
W3031622
A Left Side Indicator Set
B Right Side Indicator Set
1. Malfunction
Indicator Lamp
(MIL)
2. CHECK Lamp
3. Aftertreatment
DEF Low Lamp
4. High Exhaust
Temperature
(HEST) Lamp
5. Aftertreatment
DPF Regeneration
Required Lamp
6. Aftertreatment
DEF Tank Gauge
Mack, EPA2010 Emissions Solution
27
Instrument Cluster Icons
Aftertreatment icons are displayed on the
instrument cluster. There are 3 aftertreatment
icons:
•
•
•
Aftertreatment DPF Regeneration
Required
High Exhaust System Temperature
(HEST)
Aftertreatment DEF Tank Low Level
Indicator
DPF Regeneration Required is initiated. It
also indicates high exhaust gas temperature
during an at-speed regeneration. When
the HEST icon is illuminated, do not park
or operate the vehicle near people, or any
flammable materials, vapors, or structures.
The Aftertreatment DPF Regeneration
Required icon illuminates when the Diesel
Particulate Filter is becoming full and
regeneration is needed. The icon flashes
when the filter is full or overfull.
W3007444
High Exhaust System Temperature
(HEST) Icon
W2029416
Aftertreatment DEF Tank Low
Level Indicator (DEF)
W3007445
Aftertreatment DPF Regeneration
Required Icon
The High Exhaust System Temperature icon
illuminates when a parked Aftertreatment
The Aftertreatment DEF Tank Low Level
Indicator icon illuminates when the fluid
level is low. It also Flashes when the level
becomes critically low.
Malfunction Indicator Lamp (MIL)
W3031200
MIL Lamp
•
MIL indicates government Regulation
On Board Diagnostics (OBD) faults
•
Lamp may remain active after repair
until system operation confirms repair
28
Mack, EPA2010 Emissions Solution
Aftertreatment DEF Tank Level - Driver Warning & Inducement
Aftertreatment DEF tanks are sized to
have no less than 2 times the diesel fuel
tank mileage or hour range
The vehicle instrument cluster has a
Aftertreatment DEF Tank Level Gage
Triggers
Aftertreatment
DEF Tank Low
Level Indicator
Amber Warning
Lamp
Inducement
>12% Aftertreatment
DEF Tank Level
Gauge (>16% DEF
Remaining)
None
None
None
None
None
None
25% torque
reduction
None
5 mph Road Speed
Limit (RSL) 1
<=12%
Aftertreatment
DEF Tank Level
Gauge (~16% DEF
Remaining)
W2029416
0% Aftertreatment
DEF Tank Level
Gauge (~4% DEF
Remaining)
W2029415
0%Aftertreatment
DEF Tank Gauge
Insufficient DEF
Pump Pressure
Diesel Fuel
Refueling >15%
1
W2029415
Vehicle has to be stationary before 5 mph RSL becomes Active
Exit conditions for DEF Quality "5 mph road speed limit" Inducement:
Next 10 Engine Starts: Return to 25% torque reduction until proper DEF quality evaluation.
If poor DEF quality is detected during the next monitoring cycle then and 5 mph resumed
after vehicle stationary for 20 minutes. After 10 engine starts have been exhausted then a
Service Tool is required to exit the 5 mph RSL.
With Scan Tool DTC Clearing: Invoke 25% torque reduction until proper DEF quality
evaluation. If poor DEF Quality is detected during the next monitoring cycle then 5 mph
resumed after vehicle stationary for 20 minutes.
Mack, EPA2010 Emissions Solution
29
Aftertreatment DEF Quality - Driver Warning & Inducement
Triggers
Aftertreatment
DEF Tank Low
Level Indicator
Amber Warning
Lamp
Good DEF Quality
None
None
Poor DEF Quality
DTC Initial Detected
None
Inducement
None
None
1 2 3
W3031623
Poor DEF Quality
DTC Initial Detected
+ 10 hours
None
25% torque reduction
W3031623
Poor DEF Quality
DTC Initial Detected
+ 20 hours Diesel
Fuel Refueling
>15%
None
Temporary Exit from
5 mph Inducement
None
5 mph Road Speed
Limit (RSL) 4
W3031623
25% torque reduction
W3031623
1
2
3
4
Based on an NOx sensor evaluation of measured versus predicted SCR NOx conversion
Poor DEF Quality defined as DEF diluted with water in 50/50% proportions
Confirmation occurs during the initial OBD drive cycle
Vehicle has to be stationary before 5 mph RSL becomes Active
Exit conditions for DEF Quality "5 mph road speed limit" Inducement:
Next 10 Engine Starts: Return to 25% torque reduction until proper DEF quality evaluation.
If poor DEF quality is detected during the next monitoring cycle then and 5 mph resumed
after vehicle stationary for 20 minutes. After 10 engine starts have been exhausted then a
Service Tool is required to exit the 5 mph RSL.
With Scan Tool DTC Clearing: Invoke 25% torque reduction until proper DEF quality
evaluation. If poor DEF Quality is detected during the next monitoring cycle then 5 mph
resumed after vehicle stationary for 20 minutes.
30
Mack, EPA2010 Emissions Solution
Misfilling Diesel or Aftertreatment DEF Tanks
Although diesel fuel and Aftertreatment DEF
caps are clearly labeled and filler necks and
nozzles are different accidents can happen.
•
Costly repairs
Results of misfilling Diesel in
Aftertreatment DEF Tank
Contamination of fluids by- misfiling of
diesel or DEF in the wrong tank may result
in vehicle malfunction.
•
Aftertreatment SCR system may be
damaged by Diesel
Results of misfilling DEF in Diesel Tank
•
SCR Catalyst may be damaged by
diesel (chemical damage)
•
•
•
•
•
Emissions may be non-compliant
•
Costly repairs
•
Engine may run poorly or not at all
Injectors may be damaged
Exhaust system corrosion may
occur between turbocharger and
Aftertreatment DPF
On Board Diagnostic (OBD) Diagnostic
Trouble Codes (DTC)
On Board Diagnostic (OBD)Diagnostic
Trouble Codes (DTC)
Mack, EPA2010 Emissions Solution
31
SCR Tampering - Driver Warning & Inducement
1. Disconnected Aftertreatment DEF tank
level sensor
4. Disconnected Aftertreatment DEF pump
2. Blocked Aftertreatment DEF line or
dosing unit
5. Disconnected SCR wiring harness
3. Disconnected Aftertreatment DEF dosing
unit
6. Disconnected NOx Sensor
Triggers
Aftertreatment
DEF Tank Low
Level Indicator
Warning Lamp
Inducement
No Tampering
None
None
None
Tampering DTC
Pending 1
None
None
W3031623
Tampering DTC
Confirmed 2
None
None
W3031623
Tampering DTC
Initial Detected + 10
hour
None
25% torque
reduction
W3031623
Tampering DTC
Initial Detected + 40
hours Diesel Fuel
Refueling >15%
None
5 mph road speed
limit 3
W3031623
1
2
3
Tampering DTC Pending does not apply to DEF Tank Level Sensor
Confirmation occurs at the next OBD drive cycle
Vehicle has to be stationary before 5 mph RSL becomes Active
32
Mack, EPA2010 Emissions Solution
Exit conditions for DEF Quality "5 mph road speed limit" Inducement:
Next 10 Engine Starts: Return to 25% torque reduction until proper DEF quality evaluation.
If poor DEF quality is detected during the next monitoring cycle then and 5 mph resumed
after vehicle stationary for 20 minutes. After 10 engine starts have been exhausted then a
Service Tool is required to exit the 5 mph RSL.
With Scan Tool DTC Clearing: Invoke 25% torque reduction until proper DEF quality
evaluation. If poor DEF Quality is detected during the next monitoring cycle then 5 mph
resumed after vehicle stationary for 20 minutes.
Ambient Air Temperature (AAT)
During stationary or low vehicle speed
operation, engine fan engagement may be
required to obtain good airflow across the
AAT sensor to obtain accurate data.
CAUTION
Mack is now using the ambient air
temperature (AAT) sensor for OBD
monitoring. If a customer installs a
winterfront or blocks the radiator opening
and blocks airflow to the sensor, they will
likely set an OBD diagnostic trouble code
(DTC) for inaccurate sensor data due to
restricted airflow across the sensor.
Mack, EPA2010 Emissions Solution
33
Warranty and Maintenance
Exhaust Aftertreatment System Maintenance
The vehicle must be taken to an authorized
Mack Truck dealer to remove the ash from
the Aftertreatment Diesel Particulate Filter
and clean the Aftertreatment Doser.
Emissions Maintenance
Emissions Maintenance Interval - EPA
/ CARB defines this as the adjustment,
cleaning, repair, or replacement shall be
recommended at intervals no less than
described below.
Heavy Heavy Duty:
Injector tips (cleaning only), crankcase
ventilation valve, EGR filters and coolers:
1. If owner’s manual recommends
Afertreatment DPF replacement within
useful life, the manufacturer must pay for
the replacement; however, a random failure
within the useful life is covered only per the
above warranty provisions.
Heavy Heavy Duty:
Miles: 50,000
Hours: 1500
Injectors, Turbocharger , ECM, sensors,
actuators, EGR components (except filter and
coolers), Aftertreatment DPF plus related
components, this includes ash cleaning
Miles: 150,000
Hours: 4500
2. First maintenance interval in life of the
engine is allowed at 100,000 miles, 3000
hours.
Engine Maintenance Intervals
Component
Operation
Interval
Change
Every oil change. Under certain
conditions (for example, irregular fuel
quality), the fuel/water separator filters
may require more frequent replacement.
Water Separator
Filter Change
Every oil change. Under certain
conditions (for example, irregular fuel
quality), the fuel/water separator filters
may require more frequent replacement.
Air Cleaner
Change
Control lamp indication or 24 months,
whichever comes first
Coolant (Standard)
Change
500 000 km (300,000 miles ) or 24
months, whichever comes first
Coolant (ELC)
Change
1 000 000 km (600,000 miles) or 48
months, whichever comes first
Fuel Filter
34
Mack, EPA2010 Emissions Solution
Component
Operation
Interval
Coolant Filter (Standard)
Change
80 000 km (50,000 miles) or 6 months,
whichever comes first
Coolant Filter (ELC)
Change
240 000 km (150,000 miles) or 12
months, whichever comes first
Valves/Injectors, MP7 and
MP8
Initial Adjust
200 000 km (125,000 miles) or 12
months, whichever comes first
Injectors, MP7 and MP8
Adjust
Every 400 000 km (250,000 miles) or
24 months, whichever comes first
Valves/Injectors, MP10
Initial Adjust
100 000 km (60,000 miles) or 6 months,
whichever comes first
Injectors, MP10
Adjust
Every 200 000 km (125,000 miles) or
12 months, whichever comes first
Main drive and accessory
drive Belts, Highway Usage
MP7 and MP8
Change
500 000 km (300,000 miles) or 36
months, whichever comes first
Main drive and accessory
drive Belts, Vocational
Usage MP7 and MP8
Change
240 000 km (150,000 miles) or
12months, whichever comes first
Main drive and accessory
drive Belts, Vocational
Usage MP10
Change
500 000 km (300,000 miles) or 36
months, whichever comes first
Aftertreatment DPF Filter
Exchange
400 000 km (250,000 miles) or 4,500
hours, whichever occurs first
Aftertreatment DPF Ash
Cleaning
Clean
400 000 km (250,000 miles) or 4,500
hours, whichever occurs first
Aftertreatment Doser
Clean
240 000 km (150,000 miles) or 4,500
hours, whichever occurs first
Aftertreatment Diesel
Exhaust Fluid (DEF) Filter
Change
354 000km (220,000 miles) 7000 hours
or 3 years, whichever comes first
Mack, EPA2010 Emissions Solution
35
Oil Change Intervals
The length of time an engine can operate
before an oil change depends on the
quality oil used, the type of fuel used,
fuel consumption, engine oil consumption,
vehicle application, level of dust in the air,
and fuel consumption. The change intervals
given in this manual are maximum intervals.
If the vehicle is operating in heavy-duty
Engine Operating Condition
or severe duty operation, dusty or off-road
conditions, etc., reduce the intervals for more
frequent oil changes.
Note: Use the information in the table below
to determine the operating condition and
usage applicable to your vehicle.
Medium
Heavy
Severe
Total Fuel Consumption (mpg)
more than 6
more than 4.7
more than 3.7
Total Fuel Consumption (L/100 km)
less than 39
less than 50
less than 64
56 000
(35,000)
40 000
(25,000)
24 000
(15,000)
80 000
(50,000)
56 000
(35,000)
40 000
(25,000)
MP7 and MP8 Engine Oil and Filter
Change Interval, km (miles) — 36L (38
quart) oil capacity
MP10 Engine Oil and Filter Change
Interval, km (miles) — 42L (44 quart) oil
capacity
MP10 Engine Oil and Filter Change
Interval, km (miles) — 52L (55 quart) oil
capacity
Note: If idle time is greater than 25%, use the next lower drain interval.
For additional information about oil change
intervals, see your Mack Truck dealer. Also,
refer to Bulletin 175-60, Oil and Filters,
Mack Components.
For a complete list of approved oils, see your
Mack Truck dealer. Also, refer to Bulletin
175-61, Approved Oils, Mack Components.
36
Mack, EPA2010 Emissions Solution
Emissions Control System Warranty
The following engine components are covered by the supplemental emissions control system
warranty policy as required by the Federal emissions regulations.
1
Turbocharger Assembly
•
2
• VGT Actuator
Charge Air Cooler
•
•
•
3
4
5
6
7
8
9
10
11
12
13
14
15
CAC Pipes (Air inlet to/from
CAC)
• CAC Hoses
Injectors
Engine and Vehicle Wire harness
( connected to OBD Signal, ECM,
VECU, Instrument Cluster and
Transmission Control Module with
Vehicle Speed/Output Shaft Sensor)
EGR Mixer
EGR Cooler
EGR Valve and EGR Control Valve
EGR Pipes - Exhaust Manifold to EGR
cooler
EGR Pipes - EGR cooler to inlet
manifold
Crankcase Breather
Crankcase Separator
Crankcase Tubing and Hoses before
Separator
Aftertreatment Wiring Harness
After treatment Control Module (ACM)
Aftertreatment Diesel Particulate Filter
(DPF) Assembly
A. Aftertreatment DPF Assembly
with Diesel Oxidation Catalyst
(DOC)
•
•
•
•
Aftertreatment Doser
Diffuser Pipe (Aftertreatment
Doser mounting)
Fuel lines to Aftertreatment
Doser
Aftertreatment Fuel Shutoff
Valve
•
•
•
•
Aftertreatment Fuel Pressure
Sensor
Discharge Recirculation
Valve (DRV) (Heat Mode)
Discharge Recirculation
Valve (DRV) Solenoid
Engine EGT Sensor
Aftertreatment DPF Intake
Temperature Sensor
Aftertreatment DPF Outlet
Temperature Sensor
Aftertreatment DPF
Differential Pressure Sensor
B. Aftertreatment DPF Spark
Assisted Assembly
•
•
•
•
•
•
•
•
•
•
•
Aftertreatment DPF
Combustion Air Valve
Aftertreatment DPF
Atomization Module
Aftertreatment DPF Ignition
Coil
Aftertreatment DPF Fuel
Control Valve
Aftertreatment DPF Ignition
Electrode
Nozzle
Engine Exhaust Gas
Temperature (EGT) Sensor
Aftertreatment DPF Intake
Temperature Sensor
Aftertreatment DPF Outlet
Temperature Sensor
Aftertreatment DPF Flame
Temperature Sensor
Aftertreatment DPF
Differential Pressure Sensor
Mack, EPA2010 Emissions Solution
16
Sensors:
•
•
•
17
•
•
•
•
•
•
•
Crankshaft Position (CKP)
Camshaft Position (CMP)
Engine Coolant Temperature
(ECT)
Intake Manifold Air Temperature
Intake Manifold Pressure (IMP)
EGR Temperature
EGR Differential Pressure
Engine Coolant Level (ECL)
Vehicle Speed (VSS)
Ambient Air Temperature (AAT)
•
•
SCR Catalyst
Aftertreatment DEF Pump
SCR
•
•
•
Aftertreatment DEF Dosing
Absolute Pressure Sensor
Aftertreatment DEF Return
Valve
Aftertreatment DEF Dosing Unit
•
•
•
•
•
•
•
37
Aftertreatment DEF Tank and lines
Aftertreatment DEF Tank Heater
Valve
Aftertreatment DEF Tank
Temperature Sensor
Aftertreatment DEF Level Sensor
Aftertreatment Outlet NOx
Aftertreatment Intake NOx
Aftertreatment DEF Line Heaters
21. Vehicle Electronic Control Unit
(ECU)
22. Instrument Cluster (with ECU,
MIL, Real Time Clock, Aftertreatment
DEF Tank Gauge and, DEF Tank Low
Level Indicator)
23. Exhaust gas piping (from
turbocharger to aftertreatment)
24. Transmission Control Module
(TCM) (with Vehicle Speed / Output
Shaft Sensor
Mack Trucks, Inc.
P.O. Box 26259 Greensboro, NC 27402-6115
Mack Trucks Canada, Ltd.
2100 Derry Road West, Suite 410, Mississauga, Ontario L5N 0B3
http://www.macktrucks.com
PV776-21414253 (USA) 07.2009 © Mack Trucks, Inc. , 2009